how to weld this piece of iron on the aluminum frame?Well, my build just went from frozen turkey to fiery phoenix in a hurry. I was helping my buddy load up a bunch of scrap last night when I came across a riding lawnmower front axle his grandpa ran over with a tractor. Something about it caught my eye, so I grabbed it and a vision flashed in my head. I totally forgot to take pics of the before and most of the during, but I measured the thickness of the axle and it was 1.5 inches, the same as my bikes head tube, but it was about 3/4” shorter than the tube, and after I knocked the bronze bushings from the steer tube I found that 1" bearing cups could fit with a little coercion PERFECT! The plan is to create a bolt on head tube rake and a slight extension. I found a similar axle pic on the internet, so I drew on it where I cut it out
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To be completely honest, I did reinforce a few welds on it, but nothing that wasn't already there. Next, I used a carbide grinding bit to open up the mouth so that 1" bearing cups would fit
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Test fit. Got some trimming to do.View attachment 157388View attachment 157389
And voila! Still got lots of fitting and testing to do, but it's looking pretty darn good!View attachment 157391View attachment 157392
Now I've got to find a new fork to put on it. The ones I've been using are 1 1/8” steerer tube, now it's a 1" tube.